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Issue 03

Oct-Dec 2014

Cooling
Solutions

Inside
Foreword

In Focus

HMX a business unit of A.T.E.

Clean Talk
Interview of Mr R Srinivasan, Head of Projects,
Himalaya Drug Company

Product Showcase
Valence Valow Ink Temperature Stabiliser (ITS)

TechUpdate
EcoAxis remote monitoring for chillers

EcoTouch

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A.T.E. PRIVATE LIMITED
E: fort@ateindia.com
W: www.ateindia.com, www.ategroup.com

Foreword

In Focus
Dear Readers

HMX a business unit of A.T.E.

Welcome back to the latest


edition of GreenLink! I hope
you are all set for a great
2015. I hope you'll have a
happy and healthy year!

A breath of fresh air can work wonders. A growing


number of studies in the education, healthcare, and
manufacturing industries have shown an increase in
productivity with higher fresh air content. In a peerreviewed study in 2003, operators at a call centre in a
tropical climate zone performed nearly 9% better when
fresh air levels were increased. Ofces and dormitories
with higher fresh air content have reported lower
incidences of u and respiratory tract infection.

This issue of our newsletter


centres largely on air, in
one way or the other. A
growing body of evidence
points to the criticality of
Anuj Bhagwati, Director - A.T.E. group
good quality air in
maintaining health and in enhancing productivity. For
example, a recent study (The Light and Heat:
Productivity Co-benets of Energy Saving Technology,
February 24, 2014) points to the clear correlation
between air temperature and the productivity on 29
garment factories in and around Bengaluru. Various
studies at health care facilities around the world suggest
that higher fresh air volumes per person signicantly
reduce infection rates. From both of these examples, we
see that investing in better air quality has benets. The
capex and opex optimised energy saving technology of
HMX, which is explained in some detail in the following
sections, shows how these benets can be translated
into quick payback.
In the gravure printing process, as solvent is a major
process intermediary, the best solvent is the solvent you
never use! Valence's ITS range helps you do just this
minimise fugitive losses signicantly thus saving
money and improving air quality. The resulting payback
is startlingly fast just 6 months on solvent saving alone!
As air pollution control norms tighten, the Valence ITS
will further prove its worth as it will lower both the
capacity required for VOC treatment and operational
costs. A brief case study presented in this issue based on
early customer experience with the ITS, makes a strong
pitch for resource use efciency in the paper, lm, and foil
converting industry.

If fresh air can work


wonders, fresh cooled
air could be even
better. That precisely is
what HMX, a business
unit of A.T.E., does,
with its unique,
patented technology. It
provides fresh cooled
air for the industrial and commercial sectors that not only
ensures people comfort and thereby enhances
productivity, but also improves process efciency, all that
in an environment friendly way without the heavy power
use of air conditioners, at an affordable lifecycle cost!
To d a y m o r e a n d m o r e l a r g e c o r p o r a t e s a n d
multinationals from across segments such as
automobiles, engineering, food and beverage, etc., are
turning to HMX for innovative cooling solutions to
increase the satisfaction of their workforce, and also for
storage and process areas where treated fresh air is a
must. The resulting demand for HMX's eco-friendly
cooling solutions has resulted in a rapidly increasing
installation base that has already crossed 20 million
CFM in India.
HMX, which was earlier HMX Systems Private Limited,
has been in the business of providing eco-friendly
cooling solutions since 1999 and operates out of
Bengaluru, India. It designs and manufactures unique,

Added to this, are our regular features:


An interview (with Mr R Srinivasan, Head of
Projects, Himalaya Drug Company)
A technical write-up (on remote monitoring of
chillers)
I hope this edition of GreenLink will give you plenty of
ideas in ways by which you can improve your bottom line
through cleverer, environment friendly ways.
With best wishes,
Anuj Bhagwati
HMX-Ambiator installation

energy-efcient, and eco-friendly products for space and


process cooling. It also undertakes turnkey projects for
comfort air conditioning with its products as core. HMX's
manufacturing facility in Peenya Industrial Area,
Bengaluru, employs more than 50 skilled people and is
certied under ISO 9001:2008 for its quality practices.
Adopting some of the best manufacturing practices and
stringent quality checks, HMX rolls out products that are
best of class.

(sensible cooling no moisture addition), followed by


direct evaporative cooling (adiabatic cooling), enables
the HMX-Ambiator to deliver air cooled below the
concurrent atmospheric wet bulb temperature. Available
in various capacities starting from 10,000 CFM, the
HMX-Ambiator comes with an integrated control panel
with PLC controller and several other options such as
variable speed drives, remote monitoring, etc. It can be
used for cooling large spaces in various industries or
commercial buildings for process requirements and/or to
maintain a comfortable environment for
the staff.
At the heart of all HMX

At the heart of all HMX products is the


DAMA (Dry Air Moist Air) a patented
heat exchanger (we have received US
products is the DAMA (Dry Air
The success of the HMX-Ambiator is
and Australian patents). It's a cross ow
Moist Air) a patented cross
now followed by the recent launch of two
plate type sensible heat exchanger built
ow plate type sensible heat
more innovative pre-cooling fresh air
out of an engineering polymer, which
exchanger,
built out of an
units, the HMX-PCU-F and HMX-PCUprovides a non-corrosive, nonengineering polymer.
R. The HMX-PCU-F is an innovative
biodegradable, and anti-bacterial
technology product that supplies
substrate, and has an efciency of more
ltered, conditioned, and fresh air in designated areas.
than 80%. Supply air on one side is cooled by a
This system has 'Indirect Evaporative Cooling (IEC)' at
secondary stream of air that ows in alternating moist
the rst stage for sensible cooling and then an optional
channels. The vaporizing mass of water in the
AC coil (DX/CW) at the second stage. Incorporating IEC
secondary stream enables cooling of the supply air
at the rst stage can result in substantial energy savings.
without any water addition to the cooled air. DAMA is
It can be used as standalone solution in conjunction with
sturdily constructed to ensure trouble-free performance
AHUs/large chiller installations, with or without the AC
for several years. Also, HMX's core products do not rely
coil. It yields energy savings while introducing fresh air in
on harmful refrigerants and energy intensive
commercial buildings to improve IAQ (Indoor Air
compressors to supply cool air.
Quality). It can also be used as a pre-cooler. It nds
application across various sectors such as hospitals,
HMX's projects use different congurations to supply
auditoriums, malls, multiplexes, commercial complexes,
fresh, clean, and cool air:
gyms, ofces, sport complexes, exhibition halls, pubs,
Only Indirect Evaporative Cooling (IEC)
lounges, etc.
Combination of Indirect and Direct Evaporative
Cooling (IDEC)
The HMX-PCU-R is a next
Combination of indirect evaporative cooling and
generation heat (energy)
cooling coils (DX or chilled water)
recovery unit. Conventional
AC systems typically require
The rst of the innovative products that HMX has
10-15% of fresh air. While
introduced is the HMX-Ambiator. The HMX-Ambiator is a
inducting this fresh air, some
two stage evaporative cooling solution, which is an
conditioned air needs to be
excellent upgrade over air washers and normal
exhausted. The HMX-PCU-R
ventilation systems, as well as an energy efcient
helps in recovering the energy
alternative to conventional air conditioners. The two
from this outgoing air and prestages of cooling i.e., indirect evaporative cooling
cools the fresh air. This acts as
an energy recovery device and
HMX-PCU-R
in turn lowers the TR load on
the air conditioning system.
Since there is no silica gel type rotating wheel, there is no
wear and tear, no deterioration of efciency over time,
and no cross contamination, and no heating is required
to re-generate silica gel. Again, it can be used at hotels,
hospitals, auditoriums, malls, multiplexes, commercial
complexes, gyms, ofces, sport complexes, exhibition
halls, pubs, lounges, factories, etc., where cooled fresh
air is needed and return air is available.

HMX-PCU-F installation at TeraSpin

Having established itself as an expert in energy efcient


'cooling solutions', HMX has received accolades at
various platforms. This includes winning the 'ISHRAE

Awards of Excellence' for three consecutive years 201012 in different categories, recognition by TERI, and
nomination for the World Clean Energy Awards under
the products category at New York in May 2007.

A.T.E.: The Himalaya Drug Company has been a leading


medicinal company for several years now. Can you
please brief us about the company, its product range,
and the market it caters to?

Committed to develop the technology further, HMX has


set-up a test laboratory in Peenya. The test lab is
equipped with facilities for accurate generation of
conditioned air with desired parameters of temperature
and humidity and, testing of DAMA heat exchangers with
different secondary air, wet bulb temperature
combinations, to determine heat exchanger
performance at different conditions, etc.

Mr Srinivasan: The Himalaya Drug Company was


established by Mr M Manal in the year 1930 in
Bengaluru. We cater to the ayurvedic pharmaceutical
market. We have a wide range of products which
includes pharmaceuticals, personal care products, baby
care products, nutritional products and animal care
products, marketed under the Himalaya Wellness brand.

HMX's fast expanding customer base includes many of


the who's who of the corporate world. Some of its
customers include ABB, Alkem, Amanora, Bilcare,
Bosch, Coca Cola, Caterpillar, Dabur, DB Group, Forbes
Marshall, GE, HAL, Himalaya, Honeywell, ICC Devi
Gaurav, ICRISAT, ITC, KTTM, Lupin, NRB, Pluss
Polymer, Relaxo, SKF, Suzlon, Syntel, Tata Motors,
TeraSpin, TVS, Victor Reinz, VW, Infosys, TCPL, MBR
exibles, Apex Packaging, Jindal Polylms, Flipkart,
MRF etc. Many customers have placed repeat orders
with HMX. What attracts and brings customers back to
HMX is not just the unique technology, product quality
and performance that are indeed a class apart, but
HMX's focus on customer service. HMX has a dedicated
service set-up imbued with passion for customer service,
and has set itself a high standard for customer service.
Today, HMX works seamlessly with all units of the A.T.E.
group, ensuring a country-wide sales, service, and
project management network. With its domain expertise
and relentless efforts at customer satisfaction, HMX is
looking to grow fast.

Clean Talk
Interview of Mr R Srinivasan, Head of Projects,
Himalaya Drug Company

R Srinivasan, Head of Projects,


Himalaya Drug Company

Himalaya Drug Company,


a renowned healthcare
brand in India, has recently
installed two HMXAmbiators in its Bengaluru
plant. In an exclusive
i n t e r v i e w w i t h A . T. E .
GreenLink, Mr R
Srinivasan, Head of
Projects, Himalaya Drug
Company, talks about the
company, performance of
HMX-Ambiators, and his
experience working with
HMX.

15,000 CFM HMX-Ambiator installed at Himalaya's Bengaluru plant

A.T.E.: Could you please explain to us the problems you


faced in the storage area?
Mr Srinivasan: The storage area and the production
block area at Himalaya's state-of-the-art factory, are
spread over 25,000 ft2. Herbal raw material in the form of
granules/powder and liquid are stored here before being
taken into production. As per International Regulatory
Authorities (IRA), raw material should be stored only at
temperatures below 30 C. During the summer season
the temperature inside the storage area could soar to 38
C as it was only ventilated. This was not acceptable.
A.T.E.: What were the different cooling solutions that you
evaluated for this requirement? How did you arrive at the
conclusion that two stage cooling was ideally suited for
this application?
Mr Srinivasan: We had evaluated the feasibility of either
installing a refrigerant based air conditioning system or a
single stage evaporative air cooling system, to meet our
requirement.
Air conditioning was ruled out because of high
operational and maintenance costs. We also ruled out
the option of using a single stage evaporative cooling as
this technology would not be able to maintain
temperatures below 30 C throughout the year.
That was when we zeroed on to two stage evaporative

cooling as an ideal solution as it would help us to


maintain temperatures as per our requirement at a much
lower operational and maintenance costs. Thus, as per
the recommendations of HMX's sales team, we installed
two HMX-Ambiators of 15,000 CFM each for the storage
area.
A.T.E.: We are sure your decision to go in for the HMXAmbiator must have been taken after detailed evaluation
of other options available in the market. Could you
please tell us what were the deciding factors in favor of
the HMX-Ambiator?
Mr Srinivasan: We already have installed the HMXAmbiator for our dining area a few years ago and we are
happy with its performance. So, it has been relatively
easy for us to decide in favour of the HMX-Ambiator
because of our satisfactory experience.
Also, the application engineering based information that
we got from the HMX team made our job further easy
during the evaluation process. The detailed technical
inputs given by the HMX team convinced us beyond
doubt that this was the ideal solution for us.
A.T.E.: It is now more than a year since you have
installed the HMX-Ambiator. Has it met the requirements
initially thought of before the projects? Could you please
compare the benets of using the HMX-Ambiator
especially in your raw material section to your
expectations?
Mr Srinivasan: It has denitely met the requirements
initially thought of before the project. The primary
requirement was maintaining temperatures below 30 C
on a regular basis and we are happy to state that since
the commissioning of the HMX-Ambiators, the
temperature inside the storage area has never crossed
28 C. In a way this performance has exceeded our
expectations.
As a result of this, we
no more have to worry
a b o u t
t h e
temperature rising
beyond the IRA
standards.
A.T.E.: Could you
please share with us
your views on the
product overall, in
terms of technology, features, and aesthetics and your
suggestions for improvement?
Mr Srinivasan: This technology is a time tested
technology and we do not have an iota of doubt about the
efcacy of the HMX-Ambiator. We have seen the product
constantly evolve in terms of features and aesthetics

over the years, since we rst installed it at our dining


area.
New features like the UV ltration system for internal
water ltration, canopy on top of the machine to protect it
from rain water, PLC to monitor the operating sequence
of the machine and to identify the trip indication of
pumps, motor, sensors etc., for easy maintenance are
worth mentioning.
We have full faith in team HMX and are sure that they will
continue their endeavor of constantly improving the
product.
A.T.E.: We will be happy if you could share with us your
experience dealing with HMX in this project, from presales to installation to post-sales support and also your
suggestion for improvement.
Mr Srinivasan: Team HMX handled this project very
professionally all the way from the pre-sales period to the
post-sales period.
To start with all our queries were answered satisfactorily
during the technical evaluation process by means of
calculations and charts. After the order was placed, the
projects team skillfully used the existing ducting system,
as per our request, to put the system in place.
Their professional approach also ensured that regular
day to day operations inside the area were not
hampered.
Timely execution of the project was of essence and team
HMX diligently ensured that the entire project was
executed on time.
A.T.E.: Are you planning to go for more installations of
the HMX-Ambiator at Himalaya and if so tentatively by
when and for which section?
Mr Srinivasan: We would denitely like to go for more
installations of the HMX-Ambiator in the future, but we do
not have any immediate plans as of now.
A . T. E . : W i l l y o u
recommend the HMXAmbiator to others,
and if so why?

We will certainly recommend


the HMX-Ambiator to others in
our industry as we are glad to
be using a highly efcient
product.

Mr Srinivasan: We
will certainly
recommend the HMXAmbiator to others in our industry as we are glad to be
using a highly efcient product. We believe we have set a
standard in the pharmaceutical industry, which also adds
value to our overall image in the market.

Product Showcase
Valow Ink Temperature Stabiliser (ITS) provides big
savings in solvent consumption through ink cooling
on rotogravure and exographic printing presses
Recent studies have shown that warm ink is a major
dampener to pressroom economics. It lowers print
quality by destroying the dot structure and it causes
increased use of inks and solvents. Valence Electrons
Private Limited, an A.T.E. group
company, has developed the
Valow Ink Temperature Stabiliser
(ITS) that signicantly reduces
inks and solvents consumption and
also helps improve print quality.

clean, and highly affordable.


Result
Without a heat exchanger,
temperature of the ink
stabilised at 32 C when
productivity was at an
optimum level. On
introducing the Valow ITS,
ink temperature during
operation reduced to 28 C.
Viscosity controller
Lowering ink temperature by
4 C saw a reduction in top-up solvent consumption by
33%, while maintaining the same printing performance.
The resultant annualized savings, after installation of
Valow ITS on all eight print stations, with associated
accessories, water chilling plant, etc. translated into a
payback period of less than 6 months!

Here is a case study


Background
A leading Mumbai based converter,
manufacturing exible packaging
laminates, uses an 8 colour CI
ITS
exographic printing press for both
surface and reverse printing on 1350 mm wide lms that
run at a maximum speed of 300 m/min. Solvent based
inks, having a viscosity of 20 seconds (B4 cup) were
used. The customer sought to reduce ink and solvent
consumption, and thereby improve operating margins.
Challenge
On each print station, an ink circulating pump delivers ink
from the tank to the chamber. As the print run
progresses, temperature of the ink rose, and
subsequently stabilised at a high temperature over time.
Higher ink temperatures means higher solvent
evaporation, which results in higher top-up solvent
consumption.
Solution
The Valence technical team made an in-depth study of
the process, and deduced that a heat exchanger was
needed to reduce ink temperature to a level that reduces
solvent consumed, without hindering the process.
Critical design parameters considered were ambient
conditions, temperature and ow rate of the ink,
permissible pressure drop of the application and quantity
of heat to be transferred through the heat exchanger.
The team evaluated the application data through heat
exchange and CFD modeling to arrive at a compact
design with optimal performance. The heat exchanger
had to be dependable (leak proof) with water as the
media of heat transfer. The Valow ITS has a low
pressure drop and is sleek, simple to retrot, easy to

TechUpdate
Manage your chillers using cloud technology
Introduction
Chillers, using either vapour compression or vapour
absorption technology, are widely used in industry for
process cooling of exothermic processes and also in
facilities for de-humidication and comfort cooling.
Chillers are, however, fraught with operational
challenges of maintenance and efciency management
in order to keep the availability high and the total cost of
ownership under control. Many a time, silent losses
cause energy and maintenance costs to spiral out of
control before they are realized. Though frequent
examination of critical parameters and related expert
analysis can help identifying such losses, remote and
multiple locations of chillers in multi-plant scenarios and
the distributed nature of the installed base of OEMs pose
logistic challenges to plant owners and OEM service
experts for such exercises.
A real-time continuous and centralised information system
that tracks and analyses critical parameters and provides
analytics for users to take corrective action, goes a long
way in not only realising overall cost savings but also

Sample alerts

improving workforce efciency, productivity, and safety.


EcoAxis remote monitoring technology
EcoAxis' IoT (Internet of Things) based remote
monitoring solution with big data analytics has been
deployed by many OEMs and plant owners. This solution
is used to monitor various operating parameters of
chillers on a real time basis and allows users to access
and analyse information anytime, anywhere through
their PCs and mobile devices. As a result, it not only
helps accelerating decision making by remote experts by
assisting in problem avoidance, maintenance and
repairs, but also allows local workers take corrective
measures transforming them to problem solving experts.

Reduce MTTR (Mean Time To Repair) and increase


MTBF (Mean Time Between Failures)
Service delivery optimisation
Customer warranty and SLA compliance
Higher customer retention
Identify cross-selling and up-selling opportunities
Specic analytics related to chiller performance built
in by process experts
Performance benchmarking

How remote monitoring works


Our remote monitoring system SUPERAxis
consists of hardware & software connectors that log data
from machines, instruments, and sensors at dened
regular intervals. Using cloud-based computing, it
delivers analytics and alerts in the form of reports, dash
boards, emails and SMS any device, anytime,
anywhere.
Solution Architecture:

Runtime summary report

Key benets to end users:


Continuous monitoring of production, productivity,
availability and loses in real time
Identify and address deviations quickly
Continuous measurement and verication for energy
efciency
Real-time reporting of KPIs to keep track of
operational effectiveness and performance
Role based analytical dashboards and alerts for
quick decision support
Track and manage MTTR and MTBF
Track equipment health instill predictive/conditionbased maintenance
Benchmarking across all plants

Solution architecture

Key benets for OEMs:


Managing assets any device, any time, any where
Extend asset usable lifecycle, reliability, and
availability

Maintenance summary report

With far reaching benets, EcoAxis' IoT (Internet of


Things) based remote monitoring solution is the way
forward for optimising the performance and resource
consumption of chillers both for OEMs and end users.
Chiller performance at a glance with alerts & acts

EcoTouch
EcoAxis participates in Sugar Expo
EcoAxis participated in the 73rd annual Convention &
Sugar Expo held at Bengaluru on September 9-11,
2014. This event gave EcoAxis a good platform to
showcase its state-of-the-art solution for managing the
data from shop oor to top oor exclusively for the sugar
industry. The expo was a huge success for EcoAxis as
the customers showed keen interest in M2M remote
monitoring solution, which is quite a new and innovative
concept, especially for the sugar industry.
EcoAxis at M2M Conclave India 2014
EcoAxis participated as conference partner at the
M2M Conclave India on September 19, 2014, in
Mumbai. In India, M2M market has now started
evolving Indian M2M market will be majorly driven
by automotive & commercial telematics, household
monitoring & control, financial services & retail, smart
homes & smart metering, manufacturing,
transportation and logistics. Mr Abhay Nalawade
CEO, EcoAxis, shared his ideas regarding M2M
communication, Internet of Things, and its need for
industry. EcoAxis, which is as an established end-toend solution provider in the M2M segment received
an overwhelming response.

EcoAxis a best end-to-end solution provider


EcoAxis was awarded for being the best end-to-end
solution provider at the Automation & Robotics Show
2014 held on September 19-21, 2014 in Pune. This
show, which is a popular trade fair for the automation
industry, gave EcoAxis a good opportunity to promote
its unique M2M solutions for industrial plants. Remote
monitoring being a new concept, the stall was abuzz
with keen and potential customers.

Visit us at

on 26-28 Feb 2015


at BIEC, Bengaluru

Hall 3A
Stall 573-574

Cooling Solutions

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